US11149447B2 - PVC-plastic panel - Google Patents

PVC-plastic panel Download PDF

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Publication number
US11149447B2
US11149447B2 US16/482,917 US201716482917A US11149447B2 US 11149447 B2 US11149447 B2 US 11149447B2 US 201716482917 A US201716482917 A US 201716482917A US 11149447 B2 US11149447 B2 US 11149447B2
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polymer layer
pvc film
panel according
printing ink
carrier plate
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US20190360215A1 (en
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Dieter Döhring
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Lignum Technologies AG
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Xylo Technologies AG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
    • B05D3/061—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/40—Distributing applied liquids or other fluent materials by members moving relatively to surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D3/00—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials
    • B05D3/06—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation
    • B05D3/061—Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by exposure to radiation using U.V.
    • B05D3/065—After-treatment
    • B05D3/067—Curing or cross-linking the coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50—Multilayers
    • B05D7/52—Two layers
    • B05D7/53—Base coat plus clear coat type
    • B05D7/532—Base coat plus clear coat type the two layers being cured or baked together, i.e. wet on wet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C71/00—After-treatment of articles without altering their shape; Apparatus therefor
    • B29C71/02—Thermal after-treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0453—Ornamental plaques, e.g. decorative panels, decorative veneers produced by processes involving moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0469—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper
    • B44C5/0476—Ornamental plaques, e.g. decorative panels, decorative veneers comprising a decorative sheet and a core formed by one or more resin impregnated sheets of paper with abrasion resistant properties
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F13/00—Coverings or linings, e.g. for walls or ceilings
    • E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
    • E04F13/072—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements
    • E04F13/077—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of specially adapted, structured or shaped covering or lining elements composed of several layers, e.g. sandwich panels
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
    • E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/36—Successively applying liquids or other fluent materials, e.g. without intermediate treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/02—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber
    • B05D7/04—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to macromolecular substances, e.g. rubber to surfaces of films or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
    • B29K2027/06—PVC, i.e. polyvinylchloride
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/536—Hardness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/732—Dimensional properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B44C5/0461—Ornamental plaques, e.g. decorative panels, decorative veneers used as wall coverings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F9/00—Designs imitating natural patterns
    • B44F9/02—Designs imitating natural patterns wood grain effects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F9/00—Designs imitating natural patterns
    • B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F15/00—Flooring
    • E04F15/02—Flooring or floor layers composed of a number of similar elements
    • E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements

Definitions

  • the present invention concerns an improved panel, in particular a wall, ceiling or floor panel, based on a hard PVC (PVC-U) carrier plate, and a method for its manufacture.
  • PVC-U hard PVC
  • Polyvinyl chloride has long been used in the manufacture of floor coverings.
  • Polyvinyl chloride (PVC) is a thermoplastic material that is hard and brittle without the addition of additives.
  • PVC polyvinyl chloride
  • the mechanical properties of PVC can be adjusted over a wide range by adding suitable auxiliary materials such as plasticizers, fillers, colorants, stabilizers, etc.
  • suitable auxiliary materials such as plasticizers, fillers, colorants, stabilizers, etc.
  • PVC in this document does not refer to pure polyvinyl chloride, but to PVC with the additives normally added and necessary for practical use, unless otherwise specified.
  • a floor covering made of polyvinyl chloride is known, which is coated with a hard-wearing lacquer layer in order to improve the durability of the PVC floor covering.
  • the lacquer layer is based on an acrylate resin and is to be cured with radiation.
  • the core of this publication lies in the addition of electrically conductive substances to the acrylate resin to provide the finished floor covering with antistatic and/or electrically conductive properties.
  • the WO 2008/061791 A1 of the same applicant represents a further development of a lacquer coating.
  • the content of this publication is hereby incorporated in its entirety by reference.
  • the core of the improvement of this publication lies in the fact that two liquid, different polymer layers are applied wet-on-wet to the surface of a panel, so that a partial mixing of the coating agents takes place. These two wet-on-wet coatings are then cured together, with the cured resulting coating having a hardness gradient due to partial mixing, with the hardness of the coating decreasing with increasing depth from the surface of the resulting coating.
  • the present invention has the task of providing a panel, in particular a wall, ceiling or floor panel, comprising a carrier plate made of (in particular) hard PVC, which is to be produced in a cheaper and simpler way than is known, for example, from DE 10 2006 058 655 A1. Another task is to provide such a panel that has improved durability and high quality decorative patterns.
  • a panel comprising a carrier plate based on polyvinyl chloride and a film attached thereto, wherein the film is a PVC film having a thickness of 0.04 to 0.2 mm and comprising a decorative pattern directly printed thereon, and a cured polymer layer is provided over the PVC film.
  • the polymer layer is generally preferably based on a polymerizable resin, in particular an acrylate resin.
  • the cured polymer layer prefers a hardness gradient according to the WO 2008/061791 of the same applicant described at the beginning.
  • the carrier plate based on polyvinyl chloride consists in general preferably of hard PVC (also referred to as PVC-U), i.e. it essentially contains no or no plasticizers.
  • the present invention provides a panel that does not require a separate décor paper, as the decorative pattern is printed directly onto the PVC film.
  • the PVC film has the advantage that it is possible to dispense with expensive pre-treatment of the carrier plate (although pre-treatment is of course possible, should this be desired). In particular, there is no need to grind the surface of the carrier plate, and the application of fillers and primers, which is typically necessary in the state of the art, can also be advantageously omitted if a PVC film is used in the thickness in accordance with the invention.
  • the polymer layer comprises a hardness gradient, so that the hardness of the polymer layer decreases essentially continuously with increasing depth as seen from the surface of the polymer layer.
  • a layer with a hardness gradient is advantageous in combination with the relatively soft PVC film and, among other things, achieves good sound insulation.
  • the printing ink used for printing the decorative pattern is solvent based and preferably a UV printing ink.
  • Such printing inks slightly dissolve the surface of the PVC film, resulting in a firm anchorage of the printing ink on the film.
  • the use of UV inks also results in very good cross-linking of the ink with the surface of the PVC film. UV inks are therefore particularly preferred because they contain reactive solvents that are chemically incorporated into the later network, such as N-vinylcaprolactam.
  • a polymerizable printing ink (die) is therefore used for printing the decorative pattern, in particular based on polymerizable acrylic resins and/or N-vinylcaprolactam (a liquid reactive diluent) as offered by the company BASF.
  • the applicants have surprisingly found that improved adhesion properties of the layer system can be achieved by using polymerizable printing inks instead of the common water-based emulsion inks. This applies in particular to the preferred application with a polymer layer, especially with a hardness gradient.
  • Suitable weight proportions for the amount of polymerizable acrylate and N-vinylcaprolactam in the ink have been found to be 2 to 50, more preferred 5 to 40 and most preferred 10 to 30%. These values refer to the sum of acrylate and N-vinylcaprolactam.
  • the proportion by weight of N-vinylcaprolactam in the printing ink for example, is 3 to 12%.
  • the positive effect is particularly noticeable if the printing ink of the décor layer (i.e. the decorative pattern) and the polymer layer are cured or polymerised together (if the décor layer is printed directly on, as in digital printing, the décor layer virtually consists of the printing ink).
  • Curing of a polymer layer or a polymerizable printing ink is understood to mean the chemical reaction that takes place during polymerization.
  • the joint curing (polymerization) of the polymerizable components (acrylate systems and/or N-vinylcaprolactam) of the ink and polymer layer results in chemical crosslinking at the interface of the two layers, which is assumed to be responsible for the improved adhesion of the layers.
  • Polymerizable components which are preferably used in the present invention, include acrylates as their main components, in particular acrylate monomers, oligomers and optional photoinitiators, but also N-vinylcaprolactam as a liquid reactive diluent.
  • N-vinylcaprolactam can be added to the printing ink as a thinner in addition to the acrylates and polymerizes together with these.
  • the polymerizable components therefore essentially consist of N-vinylcaprolactam.
  • the photoinitiators effect a polymerisation of the monomers or oligomers under the influence of radiation, whereby the printing ink cures quickly.
  • the PVC film has a thickness from 0.05 to 0.15 mm, more preferably from 0.06 to 0.095 mm.
  • Such thicknesses can be processed very well and especially applied with a calender.
  • the PVC film can be applied directly using a heated calender so that the film is thermally bonded/fused to the carrier plate. The use of an additional adhesive to attach the film to the carrier plate is then not necessary, although this is possible alternatively or additionally of course.
  • the carrier plate based on polyvinyl chloride has a density of 900 to 2,500 kg/m 3 , preferably 1,000 to 2,200 kg/m 3 , more preferably 1,300 to 1,950 kg/m 3 and most preferably 1,350 to 1,500 kg/m 3 .
  • density 900 to 2,500 kg/m 3 , preferably 1,000 to 2,200 kg/m 3 , more preferably 1,300 to 1,950 kg/m 3 and most preferably 1,350 to 1,500 kg/m 3 .
  • these plates allow the incorporation of locking or coupling elements at the side edges of the plate, e.g. in order to be able to connect several similar plates with each other in a form-fitting manner.
  • a thickness (strength) for the carrier plate between 3 and 20 mm, preferably between 4 and 15 mm, more preferably between 3 and 12 mm and most preferably between 4 and 10 mm has proved to be advantageous. It has been found that these areas provide sufficient stability for the thickness of the carrier plate during the manufacturing process and also provide sufficient impact sound absorption (when used as flooring) and dimensional stability of the finished panel.
  • a layer comprising a UV primer is provided on the PVC film.
  • This layer preferably has a surface mass of 1 to 20 g/m 2 , more preferably 2 to 15 g/m 2 , and most preferably 2 to 5 g/m 2 .
  • Dipropylene glycol diacrylate has proven to be a suitable material, e.g. in an amount of 2 g/m 2 it has a good effect.
  • the primer is preferably applied to the printing ink and thus improves the adhesion between the printing ink, the substrate and the polymer layer. It has been shown that especially in areas with little ink the adhesion is improved by using the primer.
  • the carrier plate is generally preferably an extruded PVC plate.
  • abrasion-resistant particles especially corundum particles, with an average diameter of 10 to 100 ⁇ m, preferably 20 to 80 ⁇ m, more preferably 25 to 70 ⁇ m and especially 30 to 60 ⁇ m are embedded in the polymer layer.
  • the abrasion-resistant particles make it possible to considerably increase the lifetime of a panel according to the invention.
  • the decorative pattern which is applied directly to the PVC film using a digital printing process, represents the only décor layer of the panel according to the invention, i.e. no further décor papers or décor films are provided. There is therefore no need to provide a separate décor paper or the like, which leads to a considerable reduction in costs and simplification of the manufacturing process for a panel according to the invention.
  • a method of manufacturing a panel in particular a wall, ceiling or floor panel, is also provided.
  • the printing ink of the décor layer (of the decorative pattern) is cured (polymerised) together with the polymer layer applied over it, preferably by irradiating it together.
  • a carrier plate based on polyvinyl chloride with a density of 900 to 2,500 kg/m 3 is provided.
  • the carrier plate preferably consists of a hard PVC.
  • a PVC film having a thickness of 0.04 to 0.2 mm is then (ii) applied to this carrier plate by means of a calender and afterwards (iii) a decorative pattern is printed on the PVC film.
  • a liquid first polymer layer is applied to the primer layer (iv).
  • the polymer layer is cured, preferably together with the printing ink (vi).
  • at least a second polymer layer can be applied in liquid form to the still wet first polymer layer (v) so that the coating agents are partially mixed.
  • the curing of the printing ink and the polymer layer(s) can take place in one method step but also successively in two separate method steps. Hardening or curing of a polymer layer is understood to be the chemical reaction that takes place during polymerization. A distinction must be made between this and the drying of such layers, in which only the water content is reduced or removed.
  • steps (iv) to (vi) are performed such that the cured polymer layer has a hardness gradient, wherein the hardness of the coating decreases with increasing depth as seen from the surface of the resulting coating.
  • a heated calender is used in such a way that the PVC film is thermally welded to the carrier layer. In this way, the film can be applied and fastened easily and safely in a single step.
  • the directly printed decorative pattern preferably imitates a wood, stone or tile surface.
  • the PVC film is generally preferred unicoloured or white. This provides a good background colour for most commercially used decors.
  • a PVC carrier plate with a thickness of 4 mm is first provided with a primer based on a commercially available aqueous acrylic dispersion via a roller applicator.
  • the PVC carrier plate is smoothed by a roller applicator using a smoothing compound based on a highly filled aqueous acrylate dispersion.
  • a primer based on an aqueous acrylate dispersion mixed with fillers and colour pigments is applied by casting.
  • intermediate drying is carried out at temperatures between 80 and 200° C.
  • the PVC carriers treated in this way are supplied to a printing machine essentially consisting of an engraving roller and a rubber roller for transferring the print image from the engraving cylinder to the plate.
  • the print image is produced by 3 downstream printing units, whereby each printing unit applies its own printing ink consisting of ink pigments and an aqueous acrylic dispersion. For example, if a dark walnut wood is imitated, 5 g/m 2 of printing ink is applied. A commercial UV primer is then applied to the ink layer via a roller applicator. Finally, the polymer layer is applied as described in WO 2008/061791 to produce a polymer layer with a hardness gradient.
  • Example 2 “Panels where the Pattern is Printed on a PVC Film”
  • a 6 mm thick PVC carrier plate made of hard PVC is used and a PVC film with a thickness of 0.03 mm is applied to it using a heated calender, so that the film is thermally welded to the carrier plate.
  • the same décor image as in example 1 is produced using a digital printer.
  • a solvent-based, UV-curing digital printing ink is used.
  • To produce the printed image a quantity of ink of about 2 g/m 2 is required. The ink is first fixed with 150 mJ/cm 2 (mercury). Then 2 g/m 2 of a first UV-curing layer is applied, which mainly contains dipropylene glycol diacrylate.
  • a double bond containing oligomer mixed with photoinitiators is applied on this non-irradiated layer .
  • the compound is then irradiated with a UV radiation source and the polymerisable components are cured.
  • the resulting polymer layer comprises the printing ink and all layers above it.
  • FIG. 1 shows a schematic representation of a panel to according to the invention with a polyvinyl chloride carrier plate 12 ;
  • FIG. 2 shows a schematic view of a device for coating.
  • FIG. 1 the carrier plate 12 is shown, which has tongue and groove connections at its respective edges, which allow individual panels 10 to be connected with each other.
  • the carrier plate consists of an extruded hard PVC (PVC-U).
  • a PVC film 17 Above the carrier plate 12 a PVC film 17 is arranged.
  • a decorative pattern (décor layer) 18 is printed on the top side of film 17 , preferably by means of a digital printing process. This decorative pattern can be any pattern, depending on the application.
  • a UV-curable polymer layer system 19 Above the PVC film and the décor layer, a UV-curable polymer layer system 19 is provided. The illustration is not true to scale and the layers are shown here at a distance from each other not present in the real product in order to make them more clearly visible.
  • the plate 12 is considerably thicker than the layers applied to it, namely in the range of several mm, whereas the layers applied to it represent only a fraction of a mm in total.
  • FIG. 2 is used as an example to describe the manufacture of a panel according to the invention or the method according to the invention.
  • FIG. 2 schematically shows a coating device for the coating of plates 12 or for the production of panels 10 .
  • the plates 12 are made of hard PVC with a thickness of 4-8 mm.
  • the plates 12 are guided by a roller conveyor 21 through the various stations of the coating device.
  • the coating stations shown are not to be understood conclusively, but serve only as examples to explain the method according to the invention and are shown purely schematically. In front of, behind and between the stations shown, further processing stations may be provided, such as further drying stations, stations for applying primers, stations for applying fillers, etc.
  • the first station 30 is intended to be a calender unit used to apply the PVC film 17 to the top of the plates 12 .
  • the film is unwound from a supply roll 31 and attached to the top of the plates 12 by a heated calender roll 32 .
  • the film is cut to size using suitable cutting means known to a person skilled in the art (not shown).
  • a decorative décor in particular a real wood décor, is printed on PVC film 17 using digital printing.
  • a polymer layer is applied in the coating station 70 .
  • the polymer layer is applied with a hardness gradient, so that the hardness of the polymer layer decreases essentially continuously with increasing depth as seen from the surface of the polymer layer.
  • a first polymer layer based on a polymerizable acrylate system is applied in a first coating unit 71 .
  • a further wet-on-wet polymer layer is applied to this first polymer layer in Station 72 .
  • the second polymer layer for example, has a higher double bond content, as described in detail in the above-mentioned application on the hardness gradient.
  • the two polymer layers are applied wet-on-wet in stations 71 and 72 , so that partial mixing occurs at the interface of the two layers.
  • the two polymer layers are cured together under the influence of UV radiation.
  • Station 60 is preferably a digital printing station and uses a printing ink based on a polymerizable acrylate. In this case, it is preferable that no curing of the ink takes place between stations 60 and 70 , but at most an intermediate drying step during which some moisture is removed from the polymerizable acrylate of the ink. In the curing station 73 , the printing ink and the first and second polymer layers are then cured together, resulting in a particularly resistant surface.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Thermal Sciences (AREA)
  • Laminated Bodies (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Preparing Plates And Mask In Photomechanical Process (AREA)
  • Insulating Bodies (AREA)
  • Floor Finish (AREA)
  • Separation, Recovery Or Treatment Of Waste Materials Containing Plastics (AREA)
  • Aiming, Guidance, Guns With A Light Source, Armor, Camouflage, And Targets (AREA)
US16/482,917 2017-02-03 2017-02-03 PVC-plastic panel Active US11149447B2 (en)

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PCT/EP2017/052369 WO2018141400A1 (de) 2017-02-03 2017-02-03 Pvc-kunststoffpaneel

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US17/541,391 Active US11629511B2 (en) 2017-02-03 2021-12-03 Heat-treated PVC-plastic panel
US17/541,396 Active US11629512B2 (en) 2017-02-03 2021-12-03 Heat-treated PVC-plastic panel
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US17/541,380 Active US11629510B2 (en) 2017-02-03 2021-12-03 Heat-treated PVC-plastic panel
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US20220090393A1 (en) * 2017-02-03 2022-03-24 Xylo Technologies Ag Heat-treated pvc-plastic panel
US20220090395A1 (en) * 2017-02-03 2022-03-24 Xylo Technologies Ag Heat-treated pvc-plastic panel
US20220090392A1 (en) * 2017-02-03 2022-03-24 Xylo Technologies Ag Heat-treated pvc-plastic panel
US20220090394A1 (en) * 2017-02-03 2022-03-24 Xylo Technologies Ag Heat-treated pvc-plastic panel
US11629513B2 (en) * 2017-02-03 2023-04-18 Xylo Technologies Ag Heat-treated PVC-plastic panel
US11629512B2 (en) * 2017-02-03 2023-04-18 Xylo Technologies Ag Heat-treated PVC-plastic panel
US11629511B2 (en) * 2017-02-03 2023-04-18 Xylo Technologies Ag Heat-treated PVC-plastic panel
US11629510B2 (en) * 2017-02-03 2023-04-18 Xylo Technologies Ag Heat-treated PVC-plastic panel

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US11230847B2 (en) 2022-01-25
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